Wall form

ABSTRACT

Disclosed is an apparatus and method for forming a surface of a building partition having a cavity therein. The apparatus comprises an elongate support member having a first and second panel support extending substantially perpendicularly therefrom. The method comprises locating the elongate support member at a position corresponding to the surface to be formed, engaging a first panel to the front surface of the first support surface and engaging a second panel to the rear surface of the second support surface in coplanar relation to the first panel to form a first wall form. A plurality of insulated blocks may form a second form with a concrete partition to be formed between the first and second forms. The first and second panels may be removed and a facing panel secured to the second front surface of the second upright such that the concrete surface and the facing panel form a cavity therebetween.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to building construction in general and in particular to a method and apparatus for forming walls and floors.

2. Description of Related Art

In the field of construction, concrete is known to be a desirable building material for many reasons. Concrete is known to have good compressive and cohesive strength as well as noise deadening as well as a large thermal mass. These characteristics and others may make concrete a desirable choice of building materials for constructions requiring good thermal efficiency, strength, sound deadening performance and good fire ratings.

Several known difficulties with concrete construction has limited its use in residential construction. In particular, the weight of precast concrete panels has limited their use with poured in place concrete being preferable. Poured concrete structures are formed by providing groups of walls or forms, surrounding a region which defines the space that the concrete is to fill once solidified or cured. Poured concrete construction has also been limited in it's use for residential construction due to the need to construct forms completely outlining the concrete formation. Construction of such forms has typically been too time consuming and, expensive for widespread adoption for residential construction. However, due to the above favorable characteristics of concrete, it has remained a common material for use in foundations of many structures.

An additional difficulty with concrete construction has been the need to separately insulate the concrete in colder climates. One previous attempt to address the current difficulties with poured in place concrete has been the use of insulated concrete forms. Insulated concrete forms (ICF) typically comprise interlocking modular blocks that have cavities in the interior thereof. The ICF forms are dry-stacked (without mortar) such that their cavities interconnect and are thereafter filled with concrete. After the concrete cures, the insulated forms are left in place to provide permanent building insulation.

A current difficulty with ICF is the lack of provision for spaces to locate wires, plumbing and the like within a wall formed with ICF as well as difficulty in securing cladding material to the ICF wall. As ICF blocks typically form a continuous solid surface on both the inside and outside of the wall, there is no space within such a wall to run wires, pipes and the like that are required within the building. Therefore there is little to no space between the ICF blocks and a cladding material within which to locate such wire and pipes. Conduits for such use may be provided, but these are often limited in their size and location thereby limiting choices of where to locate such services within the building.

Additionally, ICF blocks may be difficult to attach cladding, such as gypsum board and the like thereto due to the low strength properties of the polystyrene used to form the ICF blocks. In particular, conventional methods of securing gypsum board to studs, such as nails and screws are not applicable to securing such boards to ICF blocks as the nails and screws will not properly attach to the polystyrene. Attempts have been made to provide securing members or ties extending through the ICF block for fastening the gypsum board fasteners to. Such attempts however have required that a user locate such ties prior to installing the gypsum board both in a horizontal as well as a vertical direction whereas with traditional studs, the user is only required to locate the stud in a vertical direction. Additionally, the use of such ties, which are commonly formed of plastic, may be prone to melting during a fire leading to the gypsum board falling and thereby potentially adding fuel to the fire.

SUMMARY OF THE INVENTION

According to a first embodiment of the present invention there is disclosed an apparatus for forming a surface of a building partition having a cavity therein. The apparatus comprises an elongate support member extending between first and second ends, a first panel support extending substantially perpendicularly from the support member along a first plane selectably engageable with a rear surface of a first forming panel and a second panel support extending substantially perpendicularly from the support member along a second plane parallel and spaced apart from the first plane, the second panel being selectably engageable with a front surface of a second wall forming panel. The first and second wall forming panels are coplanar when supported by the first and second panel supports so as to form a continuous surface with the upright for forming a wall.

The building partition is selected from the group consisting of a wall, a ceiling or a floor. The support member may form an upright. The support member may form a beam. The first forming panel may be formed integrally with the first panel support for engagement with a second panel support of an adjacent apparatus. The first and second panels may comprise rectangular panels having widths corresponding to desired spacing for wall studs.

The elongate support member may comprise a z-shaped channel comprising the first and second panels supports and a web portion therebetween. The web portion of the support member may include bores therethrough. The elongate support member may comprise a u-shaped channel. The u-shaped channel may be adapted to be oriented perpendicular to the building partition to be formed. The u-shaped channel may have a long side and a short side, the first panel support extending from the short side, the second panel support extending from the long side. The long side of the support member may include bores therethrough.

The first and second panel supports may be formed integrally with the support member. The support member and the first and second panels may be formed of sheet metal. The support member may include slots at the first and second ends sized to pass over end brackets.

According to a further embodiment of the present invention there is disclosed a kit for forming a surface of a building partition having a cavity therein. The kit comprising at least one elongate support member extending between first and second ends, the support member having a first panel support extending substantially perpendicularly therefrom along a first plane and a second panel support extending substantially perpendicularly therefrom along a second plane parallel and spaced apart from the first plane. The kit further comprises at least two wall forming panels engageable upon either a front surface of the first panel support or a rear surface of the second panel support such that the first and second wall forming panels are coplanar when supported by the first and second panel supports so as to form a continuous first surface with the support member. The kit further comprises at least one insulated block being engageable to adjacent blocks to form a second surface in parallel spaced apart relation from the first form and at least one concrete tie operable to extend from the support member to the at least one block so as to cooperatively form a concrete form between the first and second surfaces for forming a building partition.

The block may be formed of polystyrene. The block may include an embedded bracket for securing an exterior siding fastener to. The second surface of the block may include a dovetail channel for engagement with concrete to be located between the first and second surfaces.

According to a further embodiment of the present invention there is disclosed a method of forming a surface of a building partition having a cavity therein. The method comprising locating an elongate support member above a floor surface at a position corresponding to the surface to be formed, the support member having first and second vertical support surfaces extending substantially perpendicularly therefrom, engaging a first panel to the front surface of the first support surface and engaging a second panel to the rear surface of the second support. The method further comprises forming a concrete partition between the support member and the first and second panels, removing the first and second panels and securing a facing panel to a second front surface of the second upright such that the concrete surface and the facing panel form a cavity therebetween.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,

FIG. 1 is a perspective view of a system according to a first embodiment of the present invention for forming a concrete wall.

FIG. 2 is a top plan view of the system of FIG. 1.

FIG. 3 is an exploded view of the system of FIG. 1.

FIG. 4 is a perspective view of the support member of the system of FIG. 1.

FIG. 5 is a cross sectional view of the support member of FIG. 4.

FIG. 6 is a perspective view of a support member according to a further embodiment of the present invention having a u-shaped cross-section.

FIG. 7 is a cross sectional view of two interconnecting support member according to a further embodiment having wall forming panels formed integrally therewith.

DETAILED DESCRIPTION

Referring to FIG. 1, a system according to a first embodiment of the invention is shown generally at 10 for forming a concrete wall. The system 10 comprises a plurality of elongate support members 12 having wall forming panels 50 extending therebetween and a plurality of insulated blocks 100. The elongate support members and wall forming panels form a front wall form 11 for the concrete wall, the insulated blocks are arranged to form a rear wall form 13 for the concrete wall with a wall void 15 or cavity therebetween.

Turning now to FIG. 4, the elongate support members 12 are formed of a central portion 14 and first and second panels support 16 and 18, respectively. As illustrated the elongate support member 12 may have a z-shaped cross section wherein the central portion 14 forms a web connection between the first and second elongate support members 12. The first panel support 16 includes a front panel securing surface 17 and the second panel support 18 has a rear panel securing surface 19. As illustrated in FIG. 4, the first and second panel supports 16 and 18 extend in opposed directions from each other away from the central portion 14. As illustrated in FIG. 2, the first and second panel supports 16 and 18 are substantially planar members defining first and second planes which are co-planar with each other extending between the first and second ends 20 and 22 of the central portion 14 and distal panel support edges 32 and 34, respectively.

The panels 50 comprise substantially planar members extending between first and second edges 52 and 54, respectively. In some embodiments, the panels 50 may be formed of dimensional lumber such as by way of non-limiting example a length of two by twelve dimensional lumber. In other embodiments, the panels may be formed of rectangular sections of plywood, plastic, metal or any other suitable material.

As illustrated in FIG. 3, the system may include first and second end members, 60 and 70, respectively. As illustrated in FIG. 3, the first and second end members 60 and 70 may comprise top and bottom ends to the front wall form 11. In such embodiments the second or bottom end member 70 may be secured to a floor or footing (not shown) by fasteners 72 or the like extending through bores 74 therein. As illustrated, the bottom end member may comprise a section of angle bar or the like having a base portion 76 and an upright portion 78. Similarly, the second or top member 60 may be optionally secured to a ceiling or ceiling forming assembly (not shown) with fasteners 62 or the like extending through bores 64 therein and may include a base portion 66 and an upright portion 68 extending downwardly therefrom.

The first panel support 16 of the elongate support member 12 also includes a connection bore 38 extending therethrough. The connection bore 38 is sized to receive a connection pin 80 therein. As illustrated in FIG. 3, the connection pin includes an elongate cylindrical portion 82 and a flanged base 84. The cylindrical portion includes an internal threading 86 (as shown in FIG. 5). A tie rod 90 having external threading is received within the internal threading 86 of the connection pin so as to extend the tie rod perpendicularly away from the elongate support member 12 into the cavity formed between the front and rear wall forms. The tie rod 90 has a length sufficient to extend to the rear wall form and includes an end connector 96 which may include a nut or other internal threading 98 operable to engage an elongate fastener extending through the rear wall form as will be more fully described below. In operation, the connection pin 80 is passed through the connection bore 38 and tie rod 90 is threadably received therein.

With reference to FIG. 1, the insulated blocks 100 may be formed of a substantially rectangular bocks extending between first and second ends, 102 and 104, respectively and having a front surface 106. The insulated blocks 100 are maintained in their relative positions to each other by their connection with the tie rods 90 and the elongate support members 12 although it will be appreciated that the insulated blocks 100 may also be secured to each other by any known means. The insulated blocks 100 may be stacked on each other in a regular array such that their front surfaces 106 form a continuous wall form. Alternatively, the insulated blocks 100 may be stacked in alternating rows such that the horizontal connections therebetween are staggered between rows. The insulated blocks 100 may be formed of any insulating material having sufficient compressive and cohesive strength to serve as a concrete form, such as by way of non-limiting example, expanded polystyrene.

The front surface 106 of the insulated blocks 100 may have optional grooves 108 therein to provide an interlock between the insulated block 100 and concrete poured and set between the front and rear wall forms 11 and 13. As illustrated, the groove may have a dovetail cross section and may extend vertically along the front surface 106 of the blocks. Alternatively, the grooves 108 may have any other shape as desired by a user and may also extend horizontally or at an angle along the front surface 106. As illustrated in FIG. 1, the grooves 108 may also be utilized to engage with a corresponding shape of an adjacent block so as to form a corner of the rear wall form 13. The insulated blocks 100 may optionally include perpendicular slit 110 extending from the front surface 106 sized to receive an angle channel 112 therein and angled slits 118 extending from the first or second ends 102 or 104 to receive a hat-shaped channel 120 therein as illustrated in FIG. 1. The hat-shaped channel 120 may be received within the insulated block 100 such that a center portion of the hat-shaped channel 120 is located at a surface of the insulated block 100. The hat-shaped channel 120 may be utilized to secure finishing materials to the insulated blocks 100 such as a wall cladding needing to be returned from the field of the wall back towards a window or a door opening, trim or window forms.

As illustrated in FIG. 1, the insulated blocks 100 may be secured to the tie rods by passing fasteners 116 through the insulated block to engage within the internal threading 98 of the end connector 96. For embodiments having angle channels 112 therein, smaller fasteners 115 may pass through and be fastened to the angle channels 112. Optionally, boards 114 may be located adjacent to an exterior surface of the insulated blocks 100 for the fasteners 115 and 116 to pass through to fasten the insulated blocks 100 to the tie rods 90 and channel 112. After the concrete is poured a set within the cavity 15, the fasteners 115 and 116 and/or boards 114 may be removed or left in place depending upon the siding type to be applied to the exterior of the construction.

Turning now to FIG. 6, an alternative embodiment of the elongate support member 12 is illustrated formed of a central portion 150 and first and second panels support 152 and 154, respectively. The central portion 150 may comprise a u-shaped channel having first and second sides 156 and 158 walls having a connection portion 160 therebetween forming a gap 162. It will also be appreciated that the connection portion 160 may be formed of any other suitable shape, such as by way of non-limiting example solid, tubular or I-beam shaped. The first and second sides 156 and 158 extend between the connecting portion 160 and distal ends 164 and 166, respectively. The first panel support 152 extends from the distal end 164 of the first side 156 and includes a front panels securing surface 168. The second panel support 154 extends from the distal end 166 of the second side 158 and has a rear panel securing surface 170. The first and second panel supports 152 and 154 extend in opposed directions from each other away from the central portion 150. The first and second panel supports 152 and 154 are substantially planar members extending between the distal ends 164 and 166 of the first and second sides 156 and 158 to distal panel support edges 172 and 174, respectively.

The central portion 150 of the elongate support member 12 includes slots 36 extending perpendicularly thereacross each of the ends thereof. The slots 36 have a width and length sufficient to receive an end angle member therein as will be more fully described below. As illustrated, the slots 36 are positioned in the central portion 150 at a position such that an end member located therein will be adjacent to a front surface of the first panel support 152.

The central portion 150 of the elongate support member 12 also includes a transverse connection bore 180 extending therethrough. The transverse bore 180 is sized to receive a connection pin 182 therethrough. As illustrated in FIG. 3, the connection pin includes an elongate cylindrical portion 184 and a flanged base 186. The cylindrical portion includes a slot 188 therethrough sized to receive a wedge 190 therein. A tie rod 192 having a bore 194 through a first end receives the cylindrical portion 184 therethrough so as to extend the tie rod perpendicularly away from the elongate support member 12 into the cavity formed between the front and rear wall forms. The tie rod 192 has a length sufficient to extend to the rear wall form and includes an end connector 96 which may include a nut or other internal threading 98 operable to engage an elongate fastener extending through the rear wall form as will be more fully described below. In operation, the connection pin 182 is passed through the connection bore 38 and the bore 194 of the tie rod 192 passed over the cylindrical portion. The wedge 190 is then pressed into the slot 188 so as to retain the connection pin and tie rod in connection with the elongate support member 12.

With reference to FIG. 3, in operation, the system may be assembled by first locating and securing the bottom member 70 to a floor surface. Thereafter the plurality of elongate support members 12 may be located therealong. Optionally for use with u-shaped or other support members, the elongate support members may be located therealong such that the slot 36 of each elongate support member 12 receives the upright portion 78 of the bottom angle therein and secured thereto with any suitable fastening means. The plurality of panels 50 may then be secured to the elongate support members. As illustrated in FIG. 2, a first wall forming panel is secured to a front surface of the first panel support 16 and a second wall forming panel is secured to a rear surface of the second panel support 18. As illustrated in FIG. 1, a first edge 52 of a panel 50 is secured to the front panel securing surface of a panel support while the second edge 54 is secured to the rear panel securing surface 19 of an adjacent support member with fasteners or the like. Accordingly, a plurality of elongate support members 12 and panels 50 will form a continuous front form 11. Optionally, for use with a u-shaped support member 150, the upright portion 68 of a top member 60 may then be located within the slots 36 of the elongate support members 150.

As described above, a plurality of insulated blocks 100 may be stacked together to form the rear wall form 13. As also described above each of the elongate support members 12 may include a tie rod 90 extending therefrom to the insulated blocks. It will be appreciated that each elongate support member may include one or more tie rods 90. A plurality of fasteners may then be passed through the insulated blocks 100 to engage within the tie rods so as to fix the width of the cavity 15. The width of the cavity will depend upon the thickness of the concrete wall desired to be poured and formed therein.

It will also be appreciated that the elongate support members 12 and panels 50 may also be utilized to form a concrete ceiling or floor barrier. In such uses, the first and second members 60 and 70 may be secured to walls or the like with a plurality of elongate support members 12 extending horizontally therebetween. The panels 50 may then be secured to the elongate supports as described above to form a bottom form for the concrete to be poured.

After the concrete has been poured and cured, the panels 50 may be decoupled from the elongate support members 12 by removing the fasteners. The elongate support members 12 will remain secured within or to the cured concrete. It will be appreciated that as the panels formed one boundary of the concrete barrier, the removal of the panels 50 will form a void, generally indicated at 134, behind the second panel support 18 generally indicated at 130 in FIG. 5. In this type of construction the second panel support 18 may be utilized as a wall stud to fasten wall board, such as gypsum board and the like thereto thereby leaving a void behind the wall board to locate wiring, plumbing and the like therein. It will be appreciated that the width of panels 50 utilized may be selected so as to space the second panel supports 18 at a distance corresponding to standard wall stud spacing distances. Similarly, the gap 162 between the first and second panel supports may be selected to adjust the stud spacing generally indicated at 132 in FIG. 1. By way of non-limiting example, the panels 50 may be formed of 2 by 12 dimensional lumber and the gap 162 selected to be ½ inch (13 mm) due to the actual width of 2 by 12 lumber typically being 11¼ inch (286 mm) so as to maintain a 12 inch (305 mm) stud spacing 132 while allowing some tolerance for metal thickness of the elongate support member 12 as well as a small gap for ease of assembly.

As illustrated in FIG. 5, the first and second panel supports 16 and 18 are offset from each other such by an offset distance generally indicated at 136. The offset distance 136 is selected depending upon the thickness of the panels 50 to be utilized so as to maintain the plurality of panels 50 coplanar with each other and thereby to form a continuous and level concrete wall. By way of non-limiting example where the panels are selected to be 2 by 12 dimensional lumber, the offset distance may be selected to be 1½ inch (38 mm).

In alternative embodiments, the elongate support members 12 may include a plurality of holes 40 or knock out portions located within the cavity 134 so as to permit plumbing, wiring and the like to be passed through the elongate support members 12. Additionally, frangible portions 42, comprising perforations within the second side 22 may be provided to assist with removing a portion of the second side and second panel support 18 where it is desired to remove such a section for passing larger objects past the elongate support member 12 or where it is desired to intersect and form a perpendicular building partition to the existing partition. By way of non-limiting example, where it is desired to form a ceiling at that location on an existing wall it may be advantageous to remove the second sides 22 and second panel supports 18 at that location so as to enable the first member 60 to be secured directly to the concrete.

Turning now to FIG. 7, in an alternative embodiment, the elongate support member 200 may include an elongate wall forming member 206 formed integrally therewith. As illustrated, the elongate wall forming member 206 may include an upturned end portion 208 adapted to engage with and be secured to a panel support 204 of an adjacent support member 200. As illustrated in FIG. 7, the support member 200 may include a central portion 202 as described in more detail above therebetween. It will be appreciated that an apparatus according so such an embodiment will not require additional panels for forming a wall. It will also be appreciated that apparatuses according to such an embodiment may be utilized to for both front and rear portions of a wall form.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims. 

1. An apparatus for forming a surface of a building partition having a cavity therein comprising: an elongate support member extending between first and second ends; a first panel support extending substantially perpendicularly from said support member along a first plane selectably engageable with a rear surface of a first forming panel; a second panel support extending substantially perpendicularly from said support member along a second plane parallel and spaced apart from said first plane, said second panel being selectably engageable with a front surface of a second wall forming panel, such that said first and second wall forming panels are coplanar when supported by said first and second panel supports so as to form a continuous surface with said upright for forming a wall.
 2. The apparatus of claim 1 wherein said building partition is selected from the group consisting of a wall, a ceiling or a floor.
 3. The apparatus of claim 1 wherein said support member forms an upright.
 4. The apparatus of claim 1 wherein said support member forms a beam.
 5. The apparatus of claim 1 wherein said first forming panel is formed integrally with said first panel support for engagement with a second panel support of an adjacent apparatus.
 6. The apparatus of claim 5 wherein said first and second panels comprise rectangular panels having widths corresponding to desired spacing for wall studs.
 7. The apparatus of claim 1 wherein said elongate support member comprises a z-shaped channel comprising said first and second panels supports and a web portion therebetween.
 8. The apparatus of claim 7 wherein said web portion of said support member includes bores therethrough.
 9. The apparatus of claim 1 wherein said elongate support member comprises a u-shaped channel.
 10. The apparatus of claim 9 wherein said u-shaped channel is adapted to be oriented perpendicular to the building partition to be formed.
 11. The apparatus of claim 10 wherein said u-shaped channel has a long side and a short side, said first panel support extending from said short side, said second panel support extending from said long side.
 12. The apparatus of claim 11 wherein said long side of said support member includes bores therethrough.
 13. The apparatus of claim 1 wherein said first and second panel supports are formed integrally with said support member.
 14. The apparatus of claim 13 wherein said support member and said first and second panels are formed of sheet metal.
 15. The apparatus of claim 13 wherein said support member includes slots at said first and second ends sized to pass over end brackets.
 16. A kit for forming a surface of a building partition having a cavity therein comprising: at least one elongate support member extending between first and second ends, the support member having a first panel support extending substantially perpendicularly therefrom along a first plane and a second panel support extending substantially perpendicularly therefrom along a second plane parallel and spaced apart from said first plane; at least two wall forming panels engageable upon either a front surface of said first panel support or a rear surface of said second panel support, such that said first and second wall forming panels are coplanar when supported by said first and second panel supports so as to form a continuous first surface with said support member; at least one insulated block being engageable to adjacent blocks to form a second surface in parallel spaced apart relation from said first form; at least one tie operable to extend from said support member to said at least one block so as to cooperatively form a concrete form between said first and second surfaces for forming a building partition.
 17. The apparatus of claim 16 wherein said block is formed of polystyrene.
 18. The apparatus of claim 17 wherein said block includes an embedded bracket for securing an exterior siding fastener to.
 19. The apparatus of claim 16 wherein said second surface of said block includes a dovetail channel for engagement with concrete to be located between said first and second surfaces.
 20. A method of forming a surface of a building partition having a cavity therein comprising: locating an elongate support member above a floor surface at a position corresponding to the surface to be formed, the support member having first and second vertical support surfaces extending substantially perpendicularly therefrom; engaging a first panel to the front surface of the first support surface; engaging a second panel to the rear surface of the second support surface; forming a concrete partition behind said support member and said first and second panels; removing said first and second panels; and securing a facing panel to a second front surface of said second upright such that said concrete surface and said facing panel form a cavity therebetween. 